Cleaning cloth

ABSTRACT

A cleaning cloth is described made of a microfilament nonwoven weighing from 30 g/m 2  to 500 g/m 2 , the nonwoven being made from melt-spun, stretched continuous multicomponent filaments having a titer of 1.5 to 5 dtex, which are immediately laid down to form a nonwoven, and the continuous multicomponent filaments, optionally after pre-bonding, being split at least to 80% to form continuous micro-filaments having a titer of 0.05 to 1.0 dtex and bonded.

FIELD OF THE INVENTION

[0001] The present invention relates generally to cleaning cloths and,more particularly, to a cleaning cloth made of a microfilament nonwovenweighing from 30 to 500 g/m².

BACKGROUND OF INVENTION

[0002] U.S. Pat. No. 4,298,649 discloses cleaning cloths made ofnonwovens. The disclosed cleaning cloths are composed of at least twolayers of microfilaments having different average filament diameters.Mutually compatible and thermally meltable polymers are used aspolymeric raw materials for both layers. The layers are provided with abonding pattern using a thermal calendering process to keep the layerstogether.

DESCRIPTION OF THE INVENTION

[0003] The object of the present invention is to provide a cleaningcloth and a method for manufacturing a cleaning cloth that can bemanufactured in a cost-effective manner for a broad range of weights persurface area.

[0004] This object is achieved according to the present invention by acleaning cloth made of a microfilament nonwoven weighing from 30 to 500g/m². The nonwoven is made from melt-spun, stretched, continuous,multicomponent filaments having a titer of 1.5 to 5 dtex. The filamentsare immediately laid down to form a nonwoven, and the continuousmulticomponent filaments are split at least to 80% to form continuousmicro-filaments having a titer of 0.05 to 1.0 dtex and bonded. Thefilaments may be optionally pre-bonded before the step of splitting andbonding the filaments. Such a cleaning cloth has a surface structureeasily penetrated by dust and fiber particles, which are then held fast.It is therefore well suited as a cleaning cloth.

[0005] Preferably, the continuous multicomponent filament is acontinuous bicomponent filament made of two incompatible polymers. Inparticular, a polyester and a polyamide are suitable polymers. Such acontinuous bicomponent filament has good splittability into continuousmicro-filaments, resulting in an advantageous strength to weight persurface area ratio.

[0006] Preferably, the continuous multicomponent filaments have across-section with an orange-type or “pie” type multisegment structure,with the segments containing alternately one of the two incompatiblepolymers. In addition to this orange-type multisegment structure of thecontinuous multicomponent filaments, a side-by-side (s/s) arrangement ofthe incompatible polymers in the continuous multicomponent filament withtwo or more strips is also possible. The side-by-side arrangement ispreferably used for producing curled filaments. Such arrangements of theincompatible polymers in the continuous multicomponent filaments haveproven to be very easy to split.

[0007] At least one of the incompatible polymers forming the continuousmulticomponent filament preferable contains additives. Suitableadditives are coloring pigments, permanent-effect antistatic agents,fungicides, bactericides, acaricides, and/or additives affecting thehydrophilic or hydrophobic properties in amounts up to 10% eight. Thecleaning cloth made of spin-dyed fibers has good washability.Furthermore, static charges can be reduced or avoided and moisturetransport properties can be improved using the additives.

[0008] The method of manufacturing the cleaning cloth according to thepresent invention includes spinning the continuous multicomponentfilaments from a melt. The multicomponent filaments are stretched, andimmediate laid down to form a nonwoven. Optionally the non-woven issubjected to pre-bonding at this stage. Finally, the non-woven is bondedusing high-pressure fluid jets at this point which results in splittingat the same time into continuous micro-filaments having a titer of 0.05to 1.0 dtex. The cleaning cloth produced by this method has a veryuniform thickness and has an isotropic fiber distribution. Furthermore,the cleaning cloth has no tendency to delaminate and is distinguished bya higher modulus value than comparable staple fiber nonwovens.

[0009] Preferably, the continuous multicomponent filaments are bondedand split by exposing the pre-bonded nonwoven to high-pressure waterjets at least once on each side. The cleaning cloth thus obtains a highdegree of surface homogeneity and a splitting degree of the continuousmulticomponent filaments> 80%.

[0010] A particularly preferred method includes the step of spin dyingthe continuous multicomponent filaments. Fixation of the dyes in thepolymer fibers in this manner results in excellent washability.

[0011] Cleaning cloths with specific weights, and optionally additionaltreatments, are particularly suited for certain uses. For example,cleaning cloths having a weight of 40 to 240 g/m², optionally alsonapped, emerized, brushed, or spot-calendered, are preferably used asall-purpose and/or rinsing cloths. Cleaning cloths having a weight of 40to 140 g/m², optionally also imprinted, are particularly suited for useas sanitary cleaning cloths. Cleaning cloths weighing 80 to 200 g/m²,optionally also coated, embossed, and/or imprinted, are particularlysuited for use as window and/or glass cloths. Cleaning cloths weighing100 to 250 g/m², optionally also embossed and pre-impregnated with acleaning agent, are particularly suited for use as building cleaningcloths.

[0012] Cleaning cloths weighing 100 to 280 g/m², optionally also napped,emerized, brushed, and/or imprinted, are particularly suited for use asdusting cloths. Cleaning cloths weighing 140 to 500 g/m², optionallyalso napped, emerized, brushed, and/or imprinted, are particularlysuited for use as floor cloths.

[0013] Further features of the cleaning cloth according to the presentinvention are good water absorption, short drying time, and low cleaningagent consumption. These features result in good washing, hygienic andcare properties, as well as suitability as cleaning cloths, since quickdrying removes the water necessary for microbial growth, thus reducingthe development of bacteria and/or fungus colonies on the cleaningcloth.

[0014] The cleaning cloth is advantageously impregnated with a cleaningand/or care agent. Ionic or non-ionic surface active agents such assodium sulfo-succinate or the respective dioctyl ester in amounts from0.1 to 1.0 wt. % can be used as the cleaning agent. Agents containingwax or paraffin oil can be used as care agents. Pre-impregnation isparticularly useful in cleaning cloths used by professional cleaners.Pre-impregnation saves time, since constant application of new chemicalsis no longer necessary. At the same time, incorrect dosages aregenerally avoided.

[0015] The cleaning cloth according to the present invention canadvantageously be washed in boiling water (95° C.) a plurality of times.This increases the useful life of the cleaning cloth under perfectlyhygienic conditions, and usability in professional practice issimplified by machine washing of the used cleaning cloths and, ifnecessary, by pre-impregnation with cleaning and/or care agents.

[0016] The present invention is further described below in conjunctionwith two examples of a cleaning cloth built in accordance with theprinciples of the invention already discussed.

Example 1

[0017] A filament nonwoven weighing 130 g/m² is manufactured from apolyester-polyamide (PES-PA) continuous bicomponent filament. Thenonwoven subjected to water jet needle punching at a pressure of up to250 bar on both sides. After needle punching, which results in splittingof the initial filaments at the same time, the continuous bicomponentfilaments have a titer of 0.1 dtex. For cleaning cloths made ofcontinuous micro-filaments, maximum tensile forces of 450 N weremeasured in the longitudinal direction and of 340 N in the transversedirection. The modulus at 10% elongation was 142 N in the longitudinaldirection and 55 N in the transverse direction. The tear propagationforce was 15 N in the machine direction and 18 N across machinedirection.

Example 2

[0018] A filament nonwoven weighing 105 g/m² is manufactured from apolyester-polyamide (PES-PA) continuous bicomponent filament. Thenonwoven is subjected to water jet needle punching at a pressure of upto 250 bar on both sides. After needle punching, which results insplitting of the initial filaments at the same time, the continuousbicomponent filaments have a titer of 0.1 dtex. For cleaning cloths madeof continuous micro-filaments, maximum tensile forces of 336 N weremeasured in the longitudinal direction and of 279 N in the transversedirection. The modulus at 10% elongation was 93 N in the longitudinaldirection and 31 N in the transverse direction.

[0019] Table 1 shows a comparison of the mechanical properties of thetwo disclosed examples according to the present invention with those oftwo cleaning cloths made of two staple fiber nonwovens.

[0020] The maximum tensile forces in the longitudinal direction of thecleaning cloth according to the present invention were approx. 38%higher than the staple fiber nonwoven weighing 155 g/m² used for acomparison and approx. 55% higher than a staple fiber nonwoven weighing80 g/m². The cleaning cloth according to the present invention hasclearly higher modulus values and, despite its lower weight per surfacearea, has comparable tear propagation resistance values. Staple FiberStaple Fiber Example 1 Example 2 Nonwoven Nonwoven approx. approx.approx. approx. 130 g/m² 105 g/m² 155 g/m² 90 g/m² Tearing force 450 N336 N 325 N 289 N (long.) Tearing force 340 N 279 N 323 N 177 N (trans.)Elongation  49%  50%  45%  47% (long.) Elongation  53%  51%  66%  57%(trans.) Modulus 10% 142 N  93 N  67 N  37 N (long.) Modulus 10%  55 N 31 N  17 N  10 N (trans.) Tear Propag.  15 N  —  17 N  7 N Force(long.) Tear Propag.  18 N  —  17 N  11 N Force (trans.)

What is claimed is:
 1. A cleaning cloth comprising a microfilamentnonwoven weighing from 30 g/m² to 500 g/m², wherein the nonwoven is madefrom melt-spun, stretched continuous multicomponent filaments having atiter of 1.5 to 5 dtex, which are immediately laid down to form anonwoven, and the continuous multicomponent filaments, optionally afterpre-bonding, are split at least to 80% to form continuousmicro-filaments having a titer of 0.05 to 1.0 dtex and bonded.
 2. Thecleaning cloth according to claim 1 , wherein the nonwoven is made ofmelt-spun, aerodynamically stretched continuous multicomponent filamentshaving a titer of 2 to 3 dtex, which are immediately laid down to form anonwoven, and the continuous multicomponent filaments, optionally afterpre-bonding, are split at least to 80% to form continuousmicro-filaments having a titer of 0.1 to 0.5 dtex and bonded.
 3. Thecleaning cloth according to claim 1 , wherein the continuousmulticomponent filament is a continuous bicomponent filament made of twoincompatible polymers.
 4. The cleaning cloth according to claim 3 ,wherein the incompatible polymers are a polyester and a polyamide. 5.The cleaning cloth according to claim 1 , wherein the continuousmulticomponent filaments have a cross-section with an orange-typemultisegment structure, the segments containing alternately one of thetwo incompatible polymers.
 6. The cleaning cloth according to claim 1 ,wherein the continuous multicomponent filaments have a side-by-sidestructure with two or more strips.
 7. The cleaning cloth according toclaim 1 , wherein the multicomponent filaments forming the two sides ofthe cleaning cloth have different segment structures.
 8. The cleaningcloth according to claim 3 , wherein at least one of the incompatiblepolymers forming the continuous multicomponent filament containsadditives such as coloring pigments, permanent-effect antistatic agents,fungicides, bactericides, acaricides, and/or additives influencing thehydrophilic or hydrophobic properties in amounts up to 10 wt. %.
 9. Thecleaning cloth according to claim 1 , wherein the cloth weighs 40 g/m²to 240 g/m² and is suitable for use as an all purpose and/or rinsingcloth.
 10. The cleaning cloth according to claim 9 , wherein the clothis napped, emerized, brushed, or spot-calendered.
 11. The cleaning clothaccording to claim 1 , wherein the cloth weighs 80 g/m² to 200 g/m², andis suitable for use as a window and/or glass cloth.
 12. The cleaningcloth according to claim 11 , wherein the cloth is coated, embossed,and/or imprinted.
 13. The cleaning cloth according to claim 1 , whereinthe cloth weighs 100 g/m² to 250 g/m², and is suitable for use as abuilding cleaning cloth.
 14. The cleaning cloth according to claim 13 ,wherein the cloth is embossed and pre-impregnated with a cleaning agent.15. The cleaning cloth according to claim 1 , wherein the cloth weighs100 g/m² to 280 g/m², and is suitable for use as a dusting cloth. 16.The cleaning cloth according to claim 15 , wherein the cloth is napped,emerized, brushed, and/or imprinted.
 17. The cleaning cloth according toclaim 1 , wherein the cloth weighs 140 g/m² to 500 g/m², and is suitablefor use as a floor cloth.
 18. The cleaning cloth according to claim 17 ,wherein the cloth is napped, emerized, brushed, and/or imprinted. 19.The cleaning cloth according to claim 1 , wherein the cloth isimpregnated with a cleaning and/or care agent.
 20. The cleaning clothaccording to claim 1 , wherein the cleaning cloth can be washed inboiling water (95° C.) a plurality of times.
 21. A method ofmanufacturing a cleaning cloth, comprising the steps of spinningcontinuous multicomponent filaments from a melt; stretching thefilaments; laying down the filaments to form a nonwoven; bonding thenonwoven using high pressure fluid jets and splitting the filaments atthe same time into continuous micro-filaments having a titer of 0.05 to1.0 dtex.
 22. A method of manufacturing a cleaning cloth according toclaim 21 , further comprising the step of pre-bonding the nonwoven. 23.The method according to claim 22 , wherein the continuous multicomponentfilaments are bonded and split by exposing the pre-bonded nonwoven tohigh-pressure fluid jets at least once on each side.
 24. The methodaccording to claim 21 , wherein the continuous multicomponent filamentsare dyed by spin dying.
 25. The method according to claim 21 , whereintwo spin beams are used, one of which produces continuous multicomponentfilaments having a “pie” segment structure and the other producescontinuous multicomponent filaments having a side-by-side segmentstructure with two or more strips.